Extruded fibrous liquid reservoir and method of making same

ABSTRACT

The reservoir comprises a length of raw filamentary tow encased in a plastic sleeve.

nited States Patent 11 1 Dick et al. 1 Oct. 23, 1973 EXTRUDED FIBROUSLIQUID RESERVOIR [56] References Cited AND METHOD OF MAKING SAME UNITEDSTATES PATENTS Inventors: Franklin Dick, 18 Stuyvesant Oval, 2,547,541 41951 Rosenthal 401 143 New York, NY. 10009; Peter H. 3,126,095 3/1964Caines et a1. 206/835 Seckel, l4 Capron Ln., Upper 3,355,239 11/1967Albrecht 401/148 Montclair, NJ, 07043 3,428,723 2/1969 Harrington et al.264/207 3,510,934 5/1970 Koelichen 401/198 [22] Filed: Nov. 24, 1971FOREIGN PATENTS OR APPLICATIONS [21] Appl. No.: 202,026

950,243 2/1964 Great Bntam 57/27 Related US. Application Data [63]Continuation of Ser. No. 648,589, June 26, 1967, P i Ex mine George F,Lesmes abandoned- Assistant ExaminerLorraine T. Kendell AttorneyMichae1L. Dunn [52] US. Cl 161/175, 156/166, 156/244,

161/173,161/176, 401/196, 401/198 51 1m. 01 D02g 3/00, B43k 5 00 [571ABSTRACT [58] Field Of Search 161/173, 175, 176; The reservoir comprisesa length of raw filamentary tow encased in a plastic sleeve.

4 Claims, 12 Drawing Figures 1 EXTRUDED FIBROUS LIQUID RESERVOIR ANDMETHOD OF MAKING SAME This application is a continuation of co-pendingapplication Ser. No. 648,589 filed June 26, 1967, and now abandoned.

The present invention relates to improvements in liquid reservoirs and,more particularly, to a novel ink reservoir and the method of producingsame.

Like conventional writing pens, marking pens basically comprise atubular case housing an ink reservoir, and a tip connected to the inkreservoir and extending from one end of the case to transfer ink tovarious writing surfaces. Rather than being a metal penpoint however,the tip of the marking pen comprises a nib of felt or treated fibers.The ink reservoir of the marking pen also differs from conventional pensin that it usually comprises a mass of fibrous material, such as afilamentary tow, into which the ink is absorbed.

A filamentary tow is an elongated compact bundle of thousands oflongitudinally extending filaments or fibers. In a raw state, the tow isuntreated and individual fibers are transversely crimped to form hillsand valleys which register with like hills and valleys in other fibersin the tow.

To render such'tow suitable to use as ink reservoirs, and as describedin detail in U. S. Pat. Nos. 3,095,343 and 3,111,702, issued June 25,1963, and Nov. 26, 1963 respectively, it has heretofore been commonpractice to treat the raw tow by first spreading and deregistering thecrimps in the filaments or fibers in order to form a bulky mass. Thefibers are then impregnated with a solvent or glue andgathered into aconsolidated rod-like structure. The rods are then cut into suitablelengths which are impregnated with ink by dipping or injection, and theimpregnated rods are subsequently used in pens.

The foregoing ink reservoir forming process is rather elaborate,time-consuming and expensive. Moreover, the treated lengths of tow aremessy to fill and thereafter to handle, particularly during assembly ofmarking pens, since the ink is exposed on all surfaces of the rod. Thisalso causes the ink to dry out rapidly during assembly operations.Furthermore, the residual solvent often causes chemical reactions withthe ink. This requires those assembling the marking pens to exercisegreat care.

Accordingly, it is an object of the present invention to provide animproved and relatively inexpensive liquid reservoir which may berapidly and cleanly handled and assembled by unskilled personnel orautomatically by machines without loss or undesired transfer of ink fromthe ink reservoir, and without fear of subsequent chemical reactions.

Another object of the present invention is to provide an improved inkreservoir in which a freer flow of ink if accomplished.

A further object of the present invention is to provide such an inkreservoir comprising a length of raw filamentary tow encased in animpervious plastic sleeve.

Still another object of the present invention is to provide a simple andinexpensive method of producing large quantities of ink reservoirs ofthe foregoing character including forming a plastic sleeve on and arounda de-registered and then transversely compressed raw filamentary tow andcutting the plastic covered tow into suitable lengths.

An important feature of the present invention is that the liquidreservoir can be provided in two forms:

I. where the tow has receded inwardly of the ends of the plastic outersleeve thereby providing recessed ends on the reservoir; and

2. where the tow has not receded and its ends are substantially flushwith the ends of the sleeve. The reservoir with the flush ends is madeby encasing the tow in a plastic sleeve while the tow is substantiallyuntensioned longitudinally due to the tow being guided and carried by aplurality of tensioned, uncrimped yarn threads. The threads are includedwithin the plastic sleeve and aid in the flow of ink within thereservoir'because the fibers in the thread are closer together than thefibers in the crimped tow and thus the capillary flow of ink in thethreads is greater than in the tow. This permits a rapid delivery of inkto the end of the reservoir during use in writing.

The reservoir of the present invention is useful in many environmentsother than its use as an ink reservoir. For example, as a reservoir fora liquid medicine such as iodine, as a reservoir for a liquid glue, andthe like.

The foregoing, as well as other objects and advantages of the presentinvention, may be more clearly understood by reference to the followingdetailed description when considered with the drawings which, by way ofexample only, illustrate one form of marking pen, two forms of inkreservoirs, and the method of forming same.

In the drawings:

FIG. 1 is a sectional side view ofa marking pen utilizing the inkreservoir of the present invention;

FIG. 2 is an enlarged cross-sectional view taken along the line 2-2 inFIG. 1, illustrating the inner construction of the marking pen;

FIG. 3 is a perspective view of one form of the ink reservoir for themarking pen;

FIG. 4 is a sectional view taken along the line 4-4 in FIG. 3illustrating the interior of the ink reservoir;

FIG. 5 is an enlarged cross-sectional view taken along the line 5-5 inFIG. 3;

FIG. 6 is a perspective view of a second form of the ink reservoir forthe marking pen;

FIG. 7 is an enlarged cross-sectional view taken along the line 7-7 inFIG; 6;

FIG. 8 is an enlarged cross-sectional view taken on line 8-8 of FIG. 7;

FIG. 9 is a schematic representation of one method of forming the inkreservoirs for use in the marking pens of the present invention;

FIG. 10 is an enlarged sectional view of the plastic extruding machineand die portions of the process of FIG. 9 for forming the plasticcovered tow;

FIG. 11 is an enlarged cross-sectional view taken along the line 11-11in FIG. 10; and

FIG. 12 is an enlarged cross-sectional top view taken along the linel212 in FIG. 10.

In FIGS. 1 and 2, the marking pen is represented by the numeral 10 and,generally speaking, comprises a tubular case 12 housing a fibrous inkreservoir 14, and a tip 16 connected to the reservoir and extending froma forward end of the case to apply ink to writing surfaces.

The tubular case 12 includes a cylindrical barrel portion 18 and aforward end portion 19 of reduced inner and outer radial dimensionhaving a forwardly and inwardly converging outer surface adjacent itsfront end. The barrel portion 18 is internally dimensioned to tightlyreceive the ink reservoir 14 through an open rear end 21 and to firmlysupport the reservoir within the case with a forward end of thereservoir bearing against an inner annular shoulder 20 between thebarrel and forward end portions. With the ink reservoir stationed withinthe case 12, the open rear end 21 is sealed by a cylindrical plug 22having an annular flange 23 seated against the outer rear end of thebarrel.

The forward end portion 19, on the other hand, is adapted to tightlyreceive and support the ink applicator 16 including an elongatedcylindrical nib 24 and a tubular nib holder 26.

The nib holder 26 has a cylindrical main body portion 28, afrusto-conical forward end portion 30, and a rear portion 32 includinglaterally spaced, rearwardly extending arms 34 connected by a bridge 35having a pointed rear end 36. The main body portion 28 is adapted to fitsnuggly into the forward end portion 19 of the case 12 with thefrusto-conical portion 30 hearing tightly against a front end of thecase. In this position, the pointed end 36 pierces the fibrous materialcomprising the ink reservoir 14 and the arms 34 form a recess 37 in theend of the reservoir for receiving the rear end of the nib 24.

The nib 24 may be of conventional structure, such as a compressed bodyof fiber or other porous matter, and is adapted to fit snuggly into thenib holder 26 with a rear end bearing against the bridge 35 and aforward end extending forwardly beyond the end of the holder 26. In thismanner, the bridge 35 limits rearward movement of the nib 24 whilecombining with the arms 36 to form the recess 37 which permits ink toflow directly from the ink reservoir 14 into the ends and sides of thefibers comprising the rear end portion of the nib. The ink then flows bycapillary action through the nib to the pointed forward end thereof fortransfer to a writing surface.

In order for ink to flow by capillary action through the ink reservoir14 and nib 24, it is of course necessary that the marking pen 10 includea passageway for air from atmosphere to the rear end of the reservoir toreplace used ink. In the illustrated form of the marking pen 10, such apassageway is provided by an air vent 38 in the front end of the case12, a passageway 40 defined by the inner surface of the forward endportion 19 and a flat 42 on and extending the length of the main bodyportion 28 of the nib holder, and a channel 44 in the outer surface andextending the length of the ink reservoir 14. Thus arranged, air passesthrough the vent 38, passageway 40, and channel 44 to the rear end ofthe reservoir where it enters the rear of the ink reservoir 14 anddisplaces ink as it flows by capillary action from the nib 24 and to awriting surface. The replacement of the ink by the air permits thetransfer of substantially all ink from the reservoir thereby maximizingthe writing capacity and life of the marking pen 10.

In accordance with the present invention, the reservoir 14 comprises alength of transversely compressed raw crimped filamentary tow 46 encasedin a plastic sleeve 48 with the crimps in the fibers of the towderegistered from adjacent fibers. Ideally a significant portion of thefilaments are in de-registration from adjacent filaments. The crimps areof conventional type and have a known zig-zag configuration.

Since the filamentary tow 46 is encased in the plastic sleeve 48, it iseasily and cleanly handled during filling of the reservoir 14 with afluid such as ink in the preferred example. The fluid or ink is storedin the voids in the tow, since the preferred synthetic fiber from whichthe tow is made is polyester fiber which does not absorb ink or dye.Acetate fibers may also be used but are not as effective.

After filling, the plastic sleeve 48 permits clean and easy handling ofthe tow 46, particularly during insertion of the reservoir 14 into thetubular case 12. Therefore, ink reservoirs such as 14 may be cleanlyhandled either by hand or by machines and rapidly inserted into thebarrel portions of cases, such as 12, during assembly of the markingpens 10. This makes for extremely efficient assembly of the marking pens10 and corresponding reductions in the over-all costs thereof whencompared to commercially avaiable marking pens.

The fibrous, ink reservoirs 14, may be rapidly and economicallymanufactured in large quantities by the apparatus illustrateddiagrammatically in FIGS. 9 and 10 and may take the forms illustrated inFIGS. 3 through 5. Generally speaking, the apparatus comprises a funnelor guide assembly 54, a molten plastic extruding machine 56, a crosshead58, a die 60, and a cutting machine 62. With the apparatus, raw, crimpedfilamentary tow 46 (which has previously been treated in a known mannerto de-register the crimps in adjacent fibers to form a bulky absorbentmass) and circumferentially spaced uncrimped yarn or threads 80,preferably of polyester or acetate fibers, are continuously drawn intoand through the funnel assembly 54 where the tow is transverselycompressed. Then, as the compressed raw filamentary tow 46 travels withthe threads 80 from the funnel assembly into the die 60, molten plasticsuch as polyprophlene, polyethylene, polyvinylchloride, or the like, isflowed onto and around the outer surface of the tow. As the tow is drawnfrom the die 60, the plastic forms the plastic sleeve 48 therearoundhaving the channel 44 therein. The plastic covered tow is then fed tothe cutting machine 62 where it is cut into desired lengths for use inthe marking pens 10 or in other structures requiring fluid reservoirs orfilters of filamentary tow.

More particularly, and as illustrated in FIG. 10, the crosshead 58 isattached to the outlet 64 of the extruding machine 56 and includes anL-shapcd passageway 66 leading from the outlet 64 and downwardly intothe die 60 which is secured to the bottom of the crosshead.

The funnel assembly 54 includes an inner funnel 68 having an upper endextending through a top hole 72 in the crosshead 58 and secured thereinby a set screw 74. A lower end of the inner funnel 68 is of reducedinner and outer radial dimensions and extends downwardly into thecrosshead through a vertical leg of the passageway 66 and therebeyondinto the die 60. An outer funnel receives the upper end of the innerfunnel 68 and is secured thereto by a set screw 76. The outer funnel 70is adapted to receive the tow 46 through its upper open end and to guidethe tow downwardly into the die 60, the tow being transverselycompressed as it passes through the lower end of the inner funnel 68.The outer funnel 70 is also adapted to receive the threads and to guidethem along the outer surface of the tow 46 and into the die 60. Inregard to the latter, a plurality of circumferentially spaced sideopenings 84 are included in the upper end of the funnel 70 for receivingthe threads from spools 82. The threads 80 are fed downwardly along theinner surface of the funnels 70 and 68 and, as will be describedhereinafter, effectively carry the tow 46 through the funnels and die60.

As previously indicated, the die 60 is fixedly secured to the under sideof the crosshead 58 and includes a funnel-shaped passageway 78communicating with the passageway 66. The passageway 79 is thus adaptedto receive molten plastic flowing from the crosshead 58 and to directthe plastic inwardly around and onto the outer surface of thetransversely compressed tow 46 as it emanates from the lower end of theinner funnel 68. The molten plastic flows with the moving tow 46 throughthe lower portion of the passageway 78 and is pressed tightlythereagainst to form the plastic sleeve 48 encasing the tow as it isdrawn from the die 60. As illustrated most clearly in FIG. 12, the lowerportion of the passageway 78 includes a vertically extending and pointedrib 79 which forms the channel 44 in the outer surface of the sleeve 48as the encapsuled tow is drawn from the die.

As the encapsuled tow moves from the die 60 to the cutting machine 62,the plastic cools and upon reaching the cutting machine is ready forcutting, as by a conventional guillotine blade or cutter included in thecutting machine. Operation of the cutting machine 62 thus severs theencapsulated tow into the reservoirs 14 of predetermined length.

Various means may be employed to feed and draw the tow through theapparatus illustrated in FIGS. 9 and 10. For example, drive rollers (notshown) may be included in the cutting machine 62 for such a purpose. Inany case, during the process just described, the uncrimped threads 80bear almost all of the axial or longitudinal forces. exerted to draw thetow 46 through the processing apparatus. At least two such threads arenecessary to accomplish this, however, and the preferred embodiment ofFIGS. 9 and 10 shows the use of four threads 80. As the threads 80 aredrawn downwardly through the apparatus, they effectively carry thesurrounding tow through the funnels 70 and 68 and through the die 60.This, of course, avoids tensioning the tow longitudinally and produces avery even flow of the tow through the apparatus. In turn, the resultingreservoirs 14 possess very uniform inner constructions and ink storagecharacteristics.

In addition to improving the uniformity of movement of the raw tow 46through the funnel assembly 54, the uncrimped threads 80 extend alongthe inner surface of the sleeve 48 and provide paths for the flow of inkin each of the resulting reservoirs 14 which are more direct than thecrimped filamentary tow 46. Therefore, in a marking pen including suchan ink reservoir (FIGS. 1 and 2), the uncrimped threads 80 provide animmediate flow of ink to the nib 24 allowing the pen to immediately markon a writing surface upon contact therewith. Thereafter, continuous andeven flow of ink is provided to the nib 24 by the filamentary tow 46 inthe ink reservoir.

Since the tow 46 is substantially free of longitudinal tension duringformation of the ink reservoir 14 of FIGS. 3-5, a cutting of theencapsuled tow leaves the ends of the tow substantially flush with theends of the sleeve 48. By substantially flush is meant that the ends ofall or most of the fibers comprising the tow are even with the ends ofsleeve 48 and that ends of any remaining fibers are immediately adjacentthe ends of the sleeve. This is in direct contrast to the ends of thereservoirs shown in FIGS. 6-8. Such reservoirs do not incorporate thethreads 80. Therefore, to draw the raw, crimped tow 46 through thereservoir forming apparatus of FIGS. 9 and 10, the tow is pulled by thedrive rollers (not shown) and longitudinally tensioned. Accordingly,when the plastic encapsuled tow is severed in the cutting machine 62,the longitudinal tension is relaxed and the tow, due to the memory ofthe plastic material from which it is formed, effectively snaps back toits crimped state with the ends of the tow withdrawing into the ends ofthe sleeve 48 (See FIG. 8). In this regard, it is to be noted that theperipheral layer of the plastic sleeve encased filamentary tow 46 isrelatively soft as contrasted with the stiff peripheral layer of thefilamentary tow treated in accordance with conventional methods, such asthose described in the previously referred to U. S. patents. Thispermits all but the few outermost fibers in the filamentary tow 46 whichmay be bonded to the sleeve 48, to recede into the sleeve, therebyinsuring against accidental contact of the ink holding fibers withforeign objects which might otherwise result in undesired transfer ofloss of ink from the ink reservoir.

From the foregoing description, it is appreciated that the presentinvention provides an improved fluid reservoir which is simple inconstruction and which may be rapidly assembled into a marking penwithout fear of loss or transfer of ink from the ink reservoir. The inkreservoir is of unique design including a length of raw, de-registered,crimped filamentary tow encased in a plastic sleeve with opposite endsrecessed within the sleeve, or including a length of raw, crimped,deregistered filamentary tow having a plurality of uncrimped threadswithin or around the tow, and the entire side walls of the tow structureencased in a plastic sleeve.

While a particular form or marking pen, two forms of ink reservoirs, anda method of forming same have been described in some detail herein,changes and modifications may be made therein without departing from thespirit of the invention. For example, other methods and apparatus may beused in providing the sleeve 48 on the outside of the tow such ascontinuously wrapping the tow with a strip of plastic and subsequentlyheat-fusing the strips together. Accordingly, it

is intended that the present invention be limited in scope only by theterms of the following claims.

We claim:

1. A fluid reservoir adapted for use in a marking implement andincluding:

a. a transversely compressed raw synthetic filamentary tow comprising anelongated bundle of crimped deregistered longitudinally extendingfilaments, said tow having an outer surface, and,

b. an elongated shape retaining impervious plastic sleeve encapulatingsaid filamentary tow and having inner and outer surfaces, the innersurface of which is melted onto and around the outer surface of saidtow.

2. A fluid reservoir according to claim 1 wherein said filamentary towis a polyester filamentous material and said plastic sleeve furtherincludes a channel in the outer surface of said sleeve which extendssubstantially the length thereof.

3. A fluid reservoir adapted for use in a marking imc. a plurality ofsubstantially uncrimped threads plement and including: within saidplastic sleeve and extending the length a. an elongated imperviousplastic sleeve having of said filamentary tow.

inner and outer surfaces; and 4. A fluid reservoir according to claim 3wherein said b. a length of deregistered raw filamentary towcomfilamentary tow is a polyester filamentous material and prising anelongated bundle of crimped longitudisaid threads are spaced around theperiphery thereof nally extending filaments transversely compressed andbear against the inner surface of said plastic sleeve.

and confined within said plastic sleeve; and

1. A fluid reservoir adapted for use in a marking implement andincluding: a. a transversely compressed raw synthetic filamentary towcomprising an elongated bundle of crimped deregistered longitudinallyextending filaments, said tow having an outer surface, and, b. anelongated shape retaining impervious plastic sleeve encapulating saidfilamentary tow and having inner and outer surfaces, the inner surfaceof which is melted onto and around the outer surface of said tow.
 2. Afluid reservoir according to claim 1 wherein said filamentary tow is apolyester filamentous material and said plastic sleeve further includesa channel in the outer surface of said sleeve which extendssubstantially the length thereof.
 3. A fluid reservoir adapted for usein a marking implement and including: a. an elongated impervious plasticsleeve having inner and outer surfaces; and b. a length of deregisteredraw filamentary tow comprising an elongated bundle of crimpedlongitudinally extending filaments transversely compressed and confinedwithin said plastic sleeve; and c. a plurality of substantiallyuncrimped threads within said plastic sleeve and extending the length ofsaid filamentary tow.
 4. A fluid reservoir according to claim 3 whereinsaid filamentary tow is a polyester filamentous material and saidthreads are spaced around the periphery thereof and bear against theinner surface of said plastic sleeve.